U.S. patent application number 14/298435 was filed with the patent office on 2014-10-02 for injection-molded composite construct.
The applicant listed for this patent is Graphic Packaging International, Inc.. Invention is credited to Bruce Barnard, Peter W. Blaas, Kevin J. Hjort, Scott W. Middleton, Brian R. O'Hagan.
Application Number | 20140291337 14/298435 |
Document ID | / |
Family ID | 38462412 |
Filed Date | 2014-10-02 |
United States Patent
Application |
20140291337 |
Kind Code |
A1 |
O'Hagan; Brian R. ; et
al. |
October 2, 2014 |
Injection-Molded Composite Construct
Abstract
A frame is injection molded onto a group of panels to form a
container. The panels extend at least partially around, and at
least partially define, a cavity of the container.
Inventors: |
O'Hagan; Brian R.;
(Appleton, WI) ; Blaas; Peter W.; (Marion, WI)
; Middleton; Scott W.; (Oshkosh, WI) ; Hjort;
Kevin J.; (Clintonville, WI) ; Barnard; Bruce;
(Brillion, WI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Graphic Packaging International, Inc. |
Atlanta |
GA |
US |
|
|
Family ID: |
38462412 |
Appl. No.: |
14/298435 |
Filed: |
June 6, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13357295 |
Jan 24, 2012 |
8784959 |
|
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14298435 |
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|
11715718 |
Mar 8, 2007 |
8124201 |
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13357295 |
|
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60781229 |
Mar 10, 2006 |
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60834402 |
Jul 31, 2006 |
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Current U.S.
Class: |
220/675 ; 220/62;
220/678; 264/259; 264/325; 29/426.5 |
Current CPC
Class: |
B31B 2120/406 20170801;
B29K 2001/00 20130101; B23P 19/00 20130101; B29C 51/10 20130101;
B29C 65/76 20130101; B29C 66/4326 20130101; B29C 51/082 20130101;
B65D 2581/344 20130101; Y10T 428/1303 20150115; Y10T 428/1352
20150115; B29C 65/482 20130101; B31B 2105/00 20170801; B29C 51/162
20130101; B65D 1/26 20130101; B29C 65/48 20130101; B29C 65/4825
20130101; B31B 2120/407 20170801; B29C 45/14 20130101; B65D
2581/3493 20130101; B29C 2791/006 20130101; B65D 1/40 20130101;
B65D 2581/3479 20130101; B65D 2581/3498 20130101; B29C 2791/001
20130101; B29C 51/22 20130101; B29L 2031/712 20130101; B65D 81/3453
20130101; B29C 45/14475 20130101; B29K 2067/00 20130101; B65D 5/209
20130101; B65D 2581/3477 20130101; Y10T 29/49822 20150115; B65D
2581/3472 20130101; B31B 50/592 20180501; B29C 51/46 20130101 |
Class at
Publication: |
220/675 ;
29/426.5; 220/678; 220/62; 264/325; 264/259 |
International
Class: |
B65D 1/26 20060101
B65D001/26; B29C 45/14 20060101 B29C045/14; B29C 51/08 20060101
B29C051/08; B65D 1/40 20060101 B65D001/40; B23P 19/00 20060101
B23P019/00 |
Claims
1. A blank, comprising: a base panel; a plurality flaps
respectively connected to and extending outwardly from the base
panel, wherein the plurality of flaps includes a first flap and a
second flap that is adjacent to the first flap; a gap is defined
between the first and second flaps, at least an inner portion of
the gap becomes wider farther from the base panel, and the first
flap has a feature that has a reducing effect on how width of the
gap changes as a function of increased distance outwardly from the
base panel.
2. The blank of claim 1, wherein the blank is a laminate including
a releasable adhesive positioned between and at least indirectly
joining together a substrate and a polymer film.
3. The blank of claim 1, wherein: at least a portion of the blank
comprises microwave energy interactive material, paperboard and
polymer film, and the microwave energy interactive material is
positioned between the paperboard and the polymer film.
4. The blank of claim 1, wherein: the feature is a protruding
portion of the first flap, the second flap has a protruding portion
that has a reducing effect on how width of the gap changes as a
function of increased distance outwardly from the base panel, and
the protruding portion of the second flap extends farther into the
gap than does the protruding portion of the first flap.
5. The blank of claim 1, wherein the feature is a protruding
portion of the first flap, and wherein the protruding portion of
the first flap and the second flap are configured so that the
protruding portion of the first flap and a portion of the second
flap are in an overlapping relationship with respect to one another
when the blank is erected into a construct in which the gap is at
least partially maintained.
6. A construct erected from the blank of claim 5 and including an
injection-molded frame, wherein: the blank has been erected so that
the gap has been at least partially maintained, and the protruding
portion of the first flap and the portion of the second flap are in
an overlapping relationship with respect to one another; and a
portion of the frame covers the gap.
7. The construct of claim 6, wherein the gap is filled by a
protruding portion of the frame.
8. The blank of claim 1, wherein: the first flap includes an
outwardly extending edge; the second flap includes an outwardly
extending edge that is proximate to the edge of the first flap; at
least portions of the edges of the first and second flaps are
spaced apart from one another so that the gap is defined between
the edge of the first flap and the edge of the second flap; an
outer portion of the gap is farther from the base panel than the
inner portion of the gap, an inner portion of the edge of the first
flap partially defines the inner portion of the gap, an outer
portion of the edge of the first flap at least partially defines
both the outer portion of the gap and the feature, which has the
reducing effect on how the width of the gap changes as a function
of increased distance outwardly from the base panel, an angle is
defined between the inner and outer portions of the edge of the
first flap, and the angle is less than 180 degrees so that that the
angle at least partially provides the reducing effect on how width
of the gap changes as a function of distance outwardly from the
base panel.
9. The blank of claim 8, wherein the angle, which is defined
between the inner and outer portions of the edge of the first flap,
is an obtuse angle.
10. The blank of claim 8, wherein width of the inner portion of the
gap changes at a greater rate, as a function of distance outwardly
from the base panel, than width of the outer portion of the
gap.
11. The blank of claim 8, wherein with respect to extending
outwardly from the base panel, the outer portion of the edge of the
first flap extends convergently with respect to a centerline of the
gap.
12. The blank of claim 8, wherein with respect to extending
outwardly from the base panel, the outer portion of the edge of the
first flap extends divergently with respect to a centerline of the
gap.
13. The blank of claim 12, wherein: an inner portion of the edge of
the second flap partially defines the inner portion of the gap, an
outer portion of the edge of the second flap partially defines the
outer portion of the gap, and an angle of less than 180 degrees is
defined between the inner and outer portions of the edge of the
second flap, and with respect to extending outwardly from the base
panel, the outer portion of the edge of the second flap extends
convergently with respect to the centerline of the gap.
14. A method of forming a construct from the blank of claim 18, the
method comprising: closing the blank in a forming tool, so that the
blank is formed into the construct and the construct is at least
partially contained in the closed forming tool, wherein the forming
tool comprises a male mold and a female mold, and the closing of
the blank in the forming tool comprises engaging a first part of
the male mold against a portion of the blank, thereafter using at
least the first part of the male mold to at least partially force
the portion of the blank into a cavity of the female mold and
thereby partially form the construct, thereafter engaging a second
part of the male mold against a portion of the blank to further
form the construct, and moving the first part of the male mold
relative to the second part of the male mold at a period of time
that occurs during the closing of the blank in the forming tool and
is after the engaging of the first part of the male mold against
the blank.
15. The method of claim 14, wherein the closing of the blank in the
forming tool comprises engaging a first part of the female mold
against a portion of the blank, thereafter engaging a second part
of the female mold against a portion of the blank to further form
the construct, and moving the first part of the female mold
relative to the second part of the female at the period of time
that occurs during the closing of the blank in the forming tool and
is after the engaging of the first part of the female mold against
the portion of the blank
16. The method of claim 14, further comprising forming at least one
injection-molded feature on the construct while the construct is at
least partially contained in the closed forming tool.
17. A method of forming a construct from the blank of claim 1, the
method comprising: forming the construct, comprising closing the
blank in a forming tool, wherein the forming of the construct
comprises arranging a first part of the construct and a second part
of the construct so that there is an overlapping relationship
between the first part and the second part, and an edge of the
first part is positioned between the second part and a channel; and
forming an injection-molded feature on the construct, wherein the
forming of the injection-molded feature includes forcing molding
material to flow in the channel, so that the molding material flows
along the first part, then across the edge of the first part, and
then along the second part.
18. A blank, comprising: a laminate including a releasable adhesive
positioned between and at least indirectly joining together a
substrate and a polymer film; a base panel defined in the laminate;
a plurality flaps defined in the laminate, the plurality of flaps
being respectively connected to and extending outwardly from the
base panel, and the plurality of flaps comprises a first flap and a
second flap that is adjacent to the first flap; and a gap defined
between the first and second flaps.
19. The blank of claim 18, wherein: at least an inner portion of
the gap becomes wider farther from the base panel, and the first
flap has a feature that has a reducing effect on how width of the
gap changes as a function of increased distance outwardly from the
base panel.
20. The blank of claim 18, wherein: the laminate further includes
microwave energy interactive material, and the microwave energy
interactive material is positioned between the substrate and the
polymer film.
21. The blank of claim 18, wherein the substrate comprises
cellulosic material.
22. A construct erected from the blank of claim 18 and including at
least one injection-molded feature that is at least indirectly
joined to the polymer film.
23. The construct of claim 22, wherein the construct comprises a
container and the injection-molded feature comprises a band.
24. The construct of claim 22, wherein: the releasable adhesive
provides an adhesive bond between the substrate and the polymer
film; the adhesive bond between the substrate and the polymer film
has a peel strength; there is an adhesive bond between the
injection-molded feature and the polymer film; the adhesive bond
between the injection-molded feature and the polymer film has a
peel strength; the peel strength of the adhesive bond between the
substrate and the polymer film is less than the peel strength of
the adhesive bond between the injection-molded feature and the
polymer film.
25. A method of at least partially dismantling the construct of
claim 22, with the method comprising: separating the construct into
separate parts, wherein the separating of the construct comprises
separating the substrate and the polymer film from one another so
that the injection-molded feature remains at least indirectly
joined to the polymer film.
26. The method of claim 25, further comprising recycling at least
one of the parts.
27. The method of claim 25, wherein the separating of the substrate
and the polymer film from one another comprises: manually
separating the substrate and the polymer film from one another.
28. A method of forming a construct from the blank of claim 18, the
method comprising: closing the blank in a forming tool, so that the
blank is formed into the construct and the construct is at least
partially contained in the closed forming tool, wherein the forming
tool comprises a male mold and a female mold, and the closing of
the blank in the forming tool comprises engaging a first part of
the male mold against a portion of the blank, thereafter using at
least the first part of the male mold to at least partially force
the portion of the blank into a cavity of the female mold and
thereby partially form the construct, thereafter engaging a second
part of the male mold against a portion of the blank to further
form the construct, and moving the first part of the male mold
relative to the second part of the male mold at a period of time
that occurs during the closing of the blank in the forming tool and
is after the engaging of the first part of the male mold against
the blank.
29. The method of claim 28, wherein the closing of the blank in the
forming tool comprises engaging a first part of the female mold
against a portion of the blank, thereafter engaging a second part
of the female mold against a portion of the blank to further form
the construct, and moving the first part of the female mold
relative to the second part of the female at the period of time
that occurs during the closing of the blank in the forming tool and
is after the engaging of the first part of the female mold against
the portion of the blank
30. The method of claim 28, further comprising forming at least one
injection-molded feature on the construct while the construct is at
least partially contained in the closed forming tool.
31. A method of forming a construct from the blank of claim 18, the
method comprising: forming the construct, comprising closing the
blank in a forming tool, wherein the forming of the construct
comprises arranging a first part of the construct and a second part
of the construct so that there is an overlapping relationship
between the first part and the second part, and an edge of the
first part is positioned between the second part and a channel; and
forming an injection-molded feature on the construct, wherein the
forming of the injection-molded feature includes forcing molding
material to flow in the channel, so that the molding material flows
along the first part, then across the edge of the first part, and
then along the second part.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation of allowed U.S.
patent application Ser. No. 13/357,295, filed Jan. 24, 2012, which
is a divisional of U.S. patent application Ser. No. 11/715,718,
filed Mar. 8, 2007 (now issued as U.S. Pat. No. 8,124,201), which
claims the benefit of both U.S. Provisional Patent Application No.
60/781,229, filed Mar. 10, 2006, and U.S. Provisional Patent
Application No. 60/834,402, filed Jul. 31, 2006. The entire
disclosures of all of the above-referenced patent applications are
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to composite
constructs and, more particularly, the present invention relates to
cartons with injection-molded features.
[0003] A variety of constructs that are in the form of containers
are known. There is always a desire for containers that provide a
new balance of properties. For example, there is always a desire
for improvements relating to a container that is lightweight, stiff
(even when containing hot food), leakproof and cost-effective.
BRIEF SUMMARY OF SOME ASPECTS OF THE INVENTION
[0004] An aspect of the present invention is the provision of a
construct, such as a container or more specifically a tray, that
can advantageously be both lightweight and stiff (even when
containing hot food), and that is cost-effective to produce. The
container can also be leakproof. In accordance with one example of
the present invention, the container includes a group of panels
that is supported by a frame. The panels can be at least partially
formed from paperboard, and the frame can be at least partially
formed from polymeric material, so that the frame can be distinct
from the panels.
[0005] In accordance with one acceptable method, the frame can be
injection molded at least partially onto and/or around the group of
panels. More specifically, the group of panels can be arranged in a
predetermined configuration, so that the group of panels extends at
least partially around, and at least partially defines, at least
one cavity of the container. The frame can be mounted to (e.g.,
molded onto) at least portions of some of the panels, so that the
frame holds the group of panels in the predetermined
configuration.
[0006] In accordance with one example of the present invention,
corners of the container are at least partially defined by some of
the panels, and the frame advantageously extends into and seals the
corners so that that the container is substantially leakproof. The
panels can be part of a web that includes paperboard and a polymer
film that is carried by the paperboard. The polymer film and a
polymer from which the frame is constructed can be selected so that
they firmly adhere to one another, such as during an
injection-molding process. This firm adhesion between the polymer
film and the frame can advantageously enhance the leakproofness of
the container. If desired, the leakproofness can advantageously be
enhanced by forming the corners of the container so that the panels
remain at least substantially unpleated proximate the corners.
[0007] Optionally, microwave energy interactive material can be
positioned between the paperboard and the polymer film carried by
the paperboard, or a web of microwave energy interactive material
can be placed over the polymer film, or a microwave energy
interactive material can be associated with the container by way of
other means. The microwave energy interactive material can enhance
the cooking, heating, browning and/or crisping of a food item that
is contained by the container while the container is in a microwave
oven.
[0008] An aspect of the present invention relates to providing a
construct by disposing a substrate into a mold, and then injecting
a molding material, such as but not limited to polymeric material,
into the mold so that the molding material becomes fixedly attached
to the substrate. For example and not limitation, the substrate can
be paperboard, cardboard, paper, a sheet of polymeric material, or
a laminate that includes one or more of these materials.
[0009] Another aspect of the present invention relates to closing a
blank in a forming tool (e.g., mold) so that the blank is at least
partially erected during the closing of the mold, and then
injecting a molding material, such as but not limited to polymeric
material, into the closed mold so that the molding material becomes
fixedly attached to the erected blank. The solidified molding
material that is fixedly attached to the erected blank can be in
the form of a frame that at least partially holds the erected blank
in its erected configuration. The frame together with the erected
blank can be characterized as an injection-molded composite
construct. For example and not limitation, throughout this
disclosure, a construct can be characterized as being (e.g., can be
shaped to function as) a blank, container, carton, sleeve, tray, or
the like.
[0010] In accordance with one aspect of the present invention, when
the molding material is injected into the mold, the molding
material forces predetermined portions of the blank against the
forming tool (e.g., mold) and thereby forms, or at least enlarges,
channels. The molding material flows in, and solidifies in, these
channels.
[0011] Another aspect of the present invention relates to
reinforcing an injection-molded construct. In one example, the
injection-molded construct is formed from a polymeric material, and
it is reinforced with paperboard, or the like.
[0012] In accordance with one aspect of the present invention, a
container includes panels that extends at least partially around
and at least partially define a cavity of the container. These
panels include a base panel, a first side panel extending upwardly
from the base panel, and a second side panel extending upwardly
from the base panel. Edges of the first and second side panels
extend along the same elongate corner of the container such that a
gap is defined between the edges of the first and second side
panels. In addition, an overlap exists between the edges of the
first and second side panels. An injection-molded structure extends
along and at least partially defines the corner of the container.
The injection-molded structure obstructs the gap and at least
partially covers the overlap. This can advantageously both
strengthen and seal the container.
[0013] According to one aspect of the present invention, a
container includes a base panel and side panels that extend
upwardly from the base panel. The side panels extend at least
partially around and at least partially define a cavity of the
container. Multi-part flanges extend outwardly from upper edges of
side panels. Each multi-part flange typically includes a lower
flange that extends outwardly from the upper edge of the respective
side panel, an upright panel that extends upright from an outer
edge of the lower flange, and optionally also an upper flange that
extends outwardly from an upper edge of the upright panel. The
upright panel can extend vertically or be inclined with respect to
the vertical, and typically it is inclined outwardly (e.g.,
slightly outwardly). A band is injection-molded onto upper surfaces
of both the upper and lower flanges. The force of the injecting of
the molding material can at least partially bend/form the flanges,
such as by forcing them against a surface of a mold, so that the
flanges take on the shape of the subject surface of the mold. The
band can advantageously strengthen the flanges and provide a smooth
surface for sealing with a lid, cover, or the like. Typically, the
band is thicker above the lower flange than it is above the upper
flange, such that the lower flange advantageously partially defines
a relatively large channel for having molding material flow therein
during the injection molding.
[0014] According to one aspect of the present invention, a panel at
least partially defines an elongate corner of the container. The
panel includes a curved portion, and an outward surface of the
curved portion of the panel defines an outwardly projecting
protrusion of the panel. The outwardly projecting protrusion of the
panel is elongate and extends along the corner (e.g., to define a
rib). An inward surface of the curved portion of the panel defines
a recess that is elongate and extends along the corner. An
injection-molded strip extends along and at least partially defines
the corner of the container. The strip includes an outwardly
projecting protrusion that is elongate, extends along the corner,
and extends into the recess of the curved portion of the panel.
Advantageously, this arrangement can help to strengthen the
container and help to provide a smooth interior surface of the
container. Also advantageously, the rib-like protrusions of the
panels define relatively large channels for accommodating flowing
molding material during the injection molding. Also, the rib-like
protrusions of the panels can be formed by the injected molding
material forcing respective portions of the panels against
respective surfaces of a mold, so that the respective portions of
the panels bend and take on the shape of the respective surfaces of
the mold.
[0015] In one aspect of the present invention, a container includes
an elongate corner, and panels of the container include a curved
portion. An outward surface of the curved portion defines an
outwardly bulbous portion (e.g., protrusion) of the panels. An
inward surface of the curved portion defines a substantially
bowl-shaped recess. An injection-molded strip, which extends along
and at least partially defines the corner of the container,
includes an outwardly bulbous portion that extends into the
substantially bowl-shaped recess. The outwardly bulbous portion of
the panels and the outwardly bulbous portion of the strip are
positioned at a lower end of the corner. Advantageously, this
arrangement can help to strengthen the container and help to
provide a smooth interior surface of the container. Also
advantageously, the bulbous protrusions of the panels define
relatively large channels for accommodating the flowing molding
material during injection molding. Also, the bulbous protrusions of
the panels can be formed by the injected molding material forcing
respective portions of the panels against respective surfaces of a
mold, so that the respective portions of the panels bend and take
on the shape of the respective surfaces of the mold.
[0016] In accordance with one aspect of the present invention, a
blank includes a base panel and flaps that are respectively
connected to and extend outwardly from the base panel. A gap is
defined between a first of the flaps and a second of the flaps. At
least an inner portion of the gap becomes wider farther from the
base panel. The first and/or the second flap has a protruding
feature that has a reducing effect on how the width of the gap
changes as a function of increased distance outwardly from the base
panel. These protruding features may overlap in a construct erected
from the blank. Advantageously, the overlap can strengthen the
construct and/or the overlap can help to control the flow of the
molding material during the injection molding.
[0017] In accordance with one aspect of the present invention, a
construct includes a laminate including a releasable adhesive
positioned between and at least indirectly joining together a
substrate and a polymer film. At least one injection-molded feature
is at least indirectly joined to the polymer film. Advantageously,
the construct may be readily separated into separate parts (one or
both of which may be recycled). The separating can include
separating the substrate and the polymer film from one another so
that the injection-molded feature remains at least indirectly
joined to the polymer film.
[0018] One aspect of the present invention is the provision of an
apparatus for use in at least partially forming a container. The
apparatus includes a mold having a cavity with an elongate interior
corner that extends into the cavity. The interior corner includes
an elongate central region positioned between elongate recesses.
Advantageously, this configuration can help in the formation of
containers in the mold, such as containers with ribbed corners, as
discussed above. In addition or alternatively, the mold can be
configured to help provide the above-discussed bulbous
portions.
[0019] In accordance with one aspect of the present invention, a
female mold includes a cavity having a plurality of elongate
interior corners that extend into the cavity, and a male mold is
provided for being inserted into the cavity of the female mold. The
male mold includes an outer mold and an inner mold that is movably
mounted to the male outer mold for moving between an extended
configuration and a retracted configuration. The male outer mold
includes corners that extend at least partially around the male
inner mold while the male inner mold is in the retracted
configuration. The corners of the male outer mold are for being
respectively positioned in the interior corners of the cavity of
the female mold when the male mold is inserted into the cavity of
the female mold, so that the plurality of corners of the male outer
mold are respectively positioned between the interior corners of
the female mold and the male inner mold while the male mold is
inserted into the cavity of the female mold. Advantageously, this
can seek to eliminate the formation of parting lines.
[0020] In accordance with one example of a method of manufacturing,
a blank is closed in a forming tool, so that the blank is formed
into a construct that is at least partially contained in the closed
forming tool. The forming tool includes a male mold and a female
mold, and the closing of the blank in the forming tool includes
engaging a first part (e.g., nose) of the male mold against a
portion of the blank, thereafter using at least the first part of
the male mold to at least partially force the portion of the blank
into a cavity of the female mold and thereby partially form the
construct, thereafter engaging a second part (e.g., base or outer
part) of the male mold against a portion of the partially formed
construct to further form the construct, and moving the first part
of the male mold relative to the second part of the male at a
period of time that occurs during the closing of the blank in the
forming tool and is after the engaging of the first part of the
male mold against the portion of the blank. This can advantageously
allow the blank to be erected in stages.
[0021] In accordance with another example of a method of
manufacturing, the forming of a construct within a forming tool
includes arranging a first part of the construct and a second part
of the construct so that there is an overlapping relationship
between the first part and the second part, and an edge of the
first part is positioned between the second part and a channel.
Then an injection-molded feature is formed on the construct. The
forming of the injection-molded feature includes forcing molding
material into the channel, so that the molding material flows along
the first part, then across the edge of the first part, and then
along the second part. This can advantageously help to keep the
molding material on the proper side of the construct.
[0022] Other aspects and advantages of the present invention will
become apparent from the following.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] In the following, reference is made to the accompanying
drawings that are listed below. The drawings illustrate exemplary
embodiments of the present invention, and they are not necessarily
drawn to scale.
[0024] FIG. 1A is a plan view of blank in a flat configuration, in
accordance with a first exemplary embodiment of the present
invention.
[0025] FIG. 1B is a plan view of a representative portion of the
blank of FIG. 1A.
[0026] FIG. 2A is a schematic cross-sectional view of a laminate
from which the blank of FIGS. 1A and 1B can be constructed.
[0027] FIG. 2B is a schematic cross-sectional view of another
laminate from which the blank of FIGS. 1A and 1B can be
constructed.
[0028] FIG. 3 is a schematic, top plan view of a tray, wherein the
tray is constructed from the blank of FIG. 1A and a frame, in
accordance with the first embodiment.
[0029] FIG. 4 is a schematic, isolated perspective view of the
frame of the tray of FIG. 3.
[0030] FIG. 5 is a schematic cross-sectional view of the tray of
FIG. 3 taken along line 5-5 of FIG. 3, with only the cross-section
being shown, in accordance with the first embodiment.
[0031] FIG. 6 is a schematic partial view that illustrates the
exterior of a representative corner portion of the tray of FIG. 3,
with the corner portion being viewed generally from below.
[0032] FIG. 7A is a schematic view of the interior of a portion of
the corner of FIG. 6, with the upper portion of the tray having
been cut away.
[0033] FIG. 7B is like FIG. 7A, except that the corner element of
the frame that is shown in FIG. 7A has been removed.
[0034] FIG. 8A schematically illustrates a mold assembly in an open
configuration, with the blank of FIG. 1 shown in dashed lines as
being associated with the mold assembly, in accordance with the
first embodiment.
[0035] FIG. 8B is a schematic pictorial view of the mold assembly
of FIG. 8A in an open configuration.
[0036] FIG. 9 is a schematic view looking into the cavity of the
outer mold of the female mold of the mold assembly of FIGS. 8A and
8B, with a portion of the blank of FIG. 1 schematically shown in
dashed lines as being associated with the outer mold of the female
mold, in accordance with the first embodiment.
[0037] FIG. 10A schematically illustrates the mold assembly of FIG.
8A in its closed configuration, in accordance with the first
embodiment.
[0038] FIG. 10B is a schematic, isolated top plan view of a portion
of a representative corner of the blank of FIG. 1 with side panels
folded upwardly as though the blank has been partially forced into
the cavity of the female mold, in accordance with the first
embodiment.
[0039] FIG. 10C is like FIG. 10B, except that the blank has been
farther forced into the cavity of the female mold, and a longer
protruding feature of the blank is engaged to, and therefore being
folded by, the shoulder of the outer mold of the female mold, in
accordance with the first embodiment.
[0040] FIG. 11A schematically illustrates, by way of an arrow,
molding material flowing in a downstream direction through a
representative channel in the closed mold assembly, with the
flowing material interacting with a portion of the blank of FIG. 1,
in accordance with the first embodiment.
[0041] FIG. 11B is a cross-sectional view that schematically
illustrates portions of the mold assembly interacting with a
portion of the blank of FIG. 1 and a portion of the frame of FIG.
4, in accordance with the first embodiment.
[0042] FIG. 12 schematically illustrates the tray of FIG. 3
containing food and closed with a polymer film, in accordance with
the first embodiment.
[0043] FIG. 13 is similar to FIG. 11B, except that it is for a
second exemplary embodiment of the present invention.
[0044] FIG. 14 is an isolated pictorial view of an outer mold of a
male mold, in accordance with the second embodiment.
[0045] FIG. 15 is an isolated pictorial view of a nose unit of the
male mold of the second embodiment.
[0046] FIG. 16 is a schematic plan view of blank in a flat
configuration, in accordance with a third exemplary embodiment of
the present invention.
[0047] FIG. 17 is like FIG. 5, except, for example, that FIG. 17 is
for the third embodiment.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0048] In the following, exemplary embodiments of the present
invention are described in greater detail with reference to the
above-mentioned drawings, in which like numerals refer to like
parts throughout the several views.
[0049] FIG. 1 illustrates a construct, namely a blank 22, that can
be formed (e.g., cut) from laminates, such as the laminates 20, 20'
shown in FIGS. 2A and 2B, in accordance with a first exemplary
embodiment of the present invention. As best understood with
reference to FIG. 1, the blank 22 includes a base panel 24 that is
connected to intermediate panels 26 by an inner fold line 28. The
intermediate panels 26 are respectively connected to side panels
30, which can also be characterized as flaps, by intermediate fold
lines 32. Flange portions 34a-34d are respectively connected to the
side panels 30 by outer fold lines 36. Each of the flange portions
34a-34d includes a pair of closely adjacent fold lines 38. The
flange portions 34a-34d can be characterized as being portions of
the respective flaps/side panels 30. In one example, one or more of
or all of the inner fold line 28, intermediate fold lines 32, outer
fold lines 36, and closely adjacent fold lines 38 can be omitted
from the blank 22, as will be discussed in greater detail
below.
[0050] The blank 22 defines corner gaps 40, each of which is
somewhat V-shaped. In accordance with the first embodiment, each of
the corner gaps 40 and associated features are identical, except
for orientation. That is and more specifically, each of the gaps 40
and associated structures are as shown in FIG. 1B, or a mirror
image of what is shown in FIG. 1B. Other corner gap arrangements
are also within the scope of the present invention.
[0051] FIG. 1B is an enlarged view of a portion of the blank 22
that includes a representative one of the corner gaps 40. The
representative corner gap is defined by opposed, outwardly
extending inner edges 41f, 41b, and opposed, outwardly extending
end edges 90f, 90b (e.g., end edges of the flange portions 34c,
34a) that respectively extend from the inner edges. The end edges
90f, 90b respectively in conjunction with end sections of outer
edges 43f, 43b define protruding features 44f, 44b. An inner
portion of the representative corner gap 40 is defined between the
inner edges 41f, 41b so that the inner portion of the gap becomes
wider farther from the base panel 24. The end edges 90f,
90b/protruding features 44f, 44b have a reducing effect on how
width of the gap 40 changes as a function of increased distance
outwardly from the base panel 24.
[0052] Angles Af, Ab are respectively defined between the inner
edges 41f, 41b and the end edges 90f, 90b. The angles Af, Ab are
less than 180 degrees so that that angles at least partially
provide the reducing effect on how the width of the gap 40 changes
as a function of distance outwardly from the base panel 24. As
shown in the figures, the angles Af, Ab are obtuse angles. As
alluded to above and in accordance with the first embodiment, the
angles Af, Ab play a role in causing the width of the outer portion
of the gap 40 to change at a lesser rate, as a function of distance
outwardly from the base panel 24, than the width of the inner
portion of the gap. Also, the angles Af, Ab can be different. For
example, in the first embodiment the angle Af is smaller than the
angle Ab so that, with respect to extending outwardly from the base
panel 24, the end edge 90f extends convergently with respect to the
centerline CL of the gap 40, whereas the end edge 90b extends
divergently with respect to the centerline of the gap. For each of
the outer edges 43f, 43b, each of its end sections extend obliquely
with respect to its middle section. Other angles and arrangements
for defining the gaps 40 and protruding features 44f, 44b are also
within the scope of the present invention. In an alternative
embodiment of the present invention, the protruding features 44f,
44b are omitted.
[0053] As mentioned above, in the first embodiment the angle Af is
smaller than the angle Ab. At least partially as a result of this
difference in the angles Ab and Af, the protruding feature 44f of
the flange portion 34c is longer than the protruding feature 44b of
the flange portion 34a (e.g., the protruding feature 44f extends
farther into the respective gap 40 than the protruding feature
44b). Similarly and as best understood with reference to FIG. 1:
the protruding feature 44e of the flange portion 34b is longer than
the protruding feature 44a of the flange portion 34a, the
protruding feature 44g of the flange portion 34d is longer than the
protruding feature 44c of the flange portion 34b, and the
protruding feature 44h of the flange portion 34d is longer than the
protruding feature 44d of the flange portion 34c. These differences
in the protruding features 44a-44h can be advantageously utilized,
for example, when the blank 22 is erected, as will be discussed in
greater detail below.
[0054] As best understood with reference to FIG. 2A, a laminate 20
from which the blank 22 can be formed includes more than one layer,
but alternatively the laminate can be replaced with a single ply of
material, such as, but not limited to, paperboard, cardboard, paper
or a polymeric sheet. In accordance with the exemplary embodiments
of the present invention, the laminate 20 includes a polymer film
50 that is supported by, and secured to, a substrate that can be in
the form of cardboard, paperboard 52 or any other suitable
material. Alternatively, the paperboard 52 and polymer film 50 can
be replaced with any other suitable materials, for example such
that the substrate of the present invention is not limited to
paperboard or the like. Nonetheless and in accordance with the
exemplary embodiments, the substrate typically is a clay-coated
paperboard 52. As should be apparent, the paperboard 52 can be more
generally characterized as a substrate, and a suitable substrate
can include paperboard with or without typical supplemental
materials, such as coatings that can include clay coatings,
colorants, indicia and the like.
[0055] Optionally, and as shown in FIG. 2A, the polymer film 50 can
be part of a microwave interactive web 54 that is secured to the
paperboard 52 by a layer of adhesive material 56. The web 54 can
further include one or more layers of microwave energy interactive
material 58 that are secured to the polymer film 50 by one or more
layers of adhesive material 60 or by any other suitable means. The
microwave energy interactive material 58 can be incorporated in the
laminate 20/blank 22 to enhance or otherwise control the cooking
and/or heating of a food item that is contained by a container
(e.g., tray 70 of FIG. 3) that is formed from the blank 22 and
exposed to microwave energy. The optional web 54/microwave energy
interactive material 58 will be discussed in greater detail
below.
[0056] Although the polymer film 50 is described above as being
part of the web 54, it is also within the scope of the present
invention for the polymer film 50 to be adhered directly to the
paperboard 54 by way of the layer of adhesive material 56 or by any
other acceptable means, such that the one or more layers of
microwave energy interactive material 58 and associated adhesive
materials 56, 58 are omitted. For example, the film 50 can be
extruded directly onto the paperboard 52 (i.e., via an extrusion
coating process). In addition, the film 50 can be a coextruded
film, as schematically illustrated by the dashed line that is shown
as dividing the film 50 in FIG. 2A. A variety of different types of
coextrusions with differing numbers of layers and having layers
with different characteristics are within the scope of the present
invention. For example, the various layers of the coextrusion can
exhibit a wide variety of different properties such as, but not
limited to, properties related to limiting oxygen and moisture
transmission. Similarly, various markings (e.g., pictures and/or
text) and/or colors can be incorporated into, or deposited on, the
film 50 or any other portion of the blank 22 (FIG. 1) or tray 70
(FIG. 3).
[0057] If the microwave energy interactive material 58 is omitted,
the container (e.g., tray 70 of FIG. 3) formed from the blank 22
can be transparent to microwave energy. Nonetheless, such a
container that is transparent to microwave energy can still be used
in a microwave oven, and it may also be used in a conventional
oven. If a container formed from the blank 22 is to be used in a
conventional oven at high temperatures, the materials from which
the container is formed (e.g., the materials from which the blank
22 is formed) would typically be selected so that they sufficiently
withstand the high temperatures.
[0058] As should be apparent from the foregoing, a wide variety of
laminates, from which the blank 22 can be formed, are within the
scope of the present invention. For example and as described above
and shown in FIG. 2B, in a laminate 20' from which the blank 22 can
be formed, the laminate 20' can include the layer of adhesive
material 56 positioned between and joining (either directly or
indirectly) the polymer film 50 (which can be in the form of one or
more layers of polymer film, or the like) to the substrate (e.g.,
paperboard 52). As discussed above and as will be discussed in
greater detail below, microwave energy interactive material 58 can
optionally be associated with the polymer film 50.
[0059] Typically any web 54/microwave energy interactive material
58 is part of the laminate 20 before the blank 22 is cut from the
laminate, or the web 54/microwave energy interactive material 58 is
fixed to the blank 22 after the blank has been cut from the
laminate 20'. Alternatively, the microwave interactive web
54/microwave energy interactive material 58 can be applied to or
otherwise mounted to an already erected container (e.g., the tray
70 of FIG. 3). As one specific example, the microwave interactive
web can be mounted (e.g., by way of an adhesive material, heat seal
coating or any other suitable means) to interior surface(s) of the
previously formed tray 70. In this regard, incorporated herein by
reference is the entire disclosure of U.S. patent application Ser.
No. 11/715,556, filed Mar. 8, 2007.
[0060] In accordance with one example of the exemplary embodiments,
the adhesive material 56 provides a bond with such a high peel
strength that the polymer film 50, or more generally the web 54
(FIG. 2A), cannot be separated from (e.g., peeled or stripped off
of) the paperboard 52 without pulling fibers, or groups of fibers,
from the paperboard 52. In contrast and accordance with another
example of the exemplary embodiments, the adhesive material 56 is a
releasable adhesive material that provides a bond with a lower peel
strength, so that the polymer film 50, or more generally the web 54
(FIG. 2A), can be more easily separated from (e.g., peeled or
stripped off of) the paperboard 52, such as without pulling fibers,
or groups of fibers, (e.g., without pulling a substantial amount of
fibers) from the paperboard 52. Peel strength is discussed in ASTM
D903-98 (2004) entitled "Standard Test Method for Peel or Stripping
Strength of Adhesive Bonds".
[0061] Typically, the adhesive material 56 will be selected/applied
in a manner so that it provides a peel strength that is
sufficiently strong so that the polymer film 50/web 54 does not
inadvertently become separated from the paperboard 52 at an
undesirable time. In accordance with one acceptable method of the
exemplary embodiments, it is not desirable for the polymer film
50/web 54 to separated from the paperboard 52 until after a user
has finished using a construct (e.g., the tray 70 of FIG. 3) that
is at least partially formed from the laminate 20 or 20', such as
for cooking food therein. For example and in accordance with one
acceptable method that can facilitate recycling of materials, when
the tray 70 includes the adhesive material 56 that is in the form
of a releasable adhesive, a user can manually separate (e.g.,
separate by the use of his or her hands) the tray 70 by separating
the paperboard 52 from the polymer film 50/web 54. Typically an
injection-molded feature, which can be in the form of a polymeric
frame 72 schematically shown in isolation in FIG. 4, is adhered
solely to the polymer film 50/web 54 and will remain adhered to the
polymer film 50/web 54, such that the adhesive bond between the 72
polymeric frame and the polymer film 50/web 54 has a greater peel
strength than the adhesive bond provided by the adhesive material
56 (e.g., between the paperboard 52 and polymer film 50/web
54).
[0062] Typically a releasable adhesive material 56 will be selected
that will provide for substantially clean separation between the
paperboard 52 and polymer film 50/web 54, so that the separated
paperboard 52 does not include any of, or significant remnants of,
the polymer film 50/web 54, and the separated polymer film 50/web
54 does not include any of, or significant remnants of, the
paperboard 52. In accordance with one example, the separated
paperboard 52 and/or the separated polymer film 50/web 54
(typically along with the polymeric frame 72 or the like still
adhered thereto) are recycled. Therefore, and in accordance with
this example, the separated part not including "any of, or
significant remnants of," the other separated part means that the
separated parts are sufficiently clean after separation so that
they can be recycled in a conventional manner, without any more
than the typical sorting and/or washing that is typically required
for post-consumer recycling. Recycling typically involves breaking
something down and making it suitable for reuse.
[0063] In addition or alternatively, for facilitating the releasing
of the adhesive material 56 if desired, a release coating can be
positioned between the adhesive material 56 and the paperboard 52
and/or polymer film 50/web 54, so that the release coating in
combination with the adhesive material 56 enables separating the
paperboard 52 and polymer film 50/web 54. In one example, such a
release coating together with the adhesive material 56 can be
cooperative so that the adhesive material 56 (e.g., such as an
adhesive material that is not typically releasable without the
release coating) can be referred to as a releasable adhesive.
[0064] The adhesive material 56 and the above-discussed optional
release coating that can be cooperative with the adhesive material
56 can both be selected from a wide variety of commercially
available materials. For example and as discussed above, the
adhesive material 56 can "in and of itself" be a releasable
adhesive material, such as a pressure sensitive releasable adhesive
material, a polar adhesive polymer that is releasable (e.g., is not
too polar), or the like or any combination thereof. In one example,
an acceptable adhesive material 56 may be Royal 20164 or 20113
brand adhesive material, which is available from Royal Adhesives
and Sealants LLC of South Bend, Ind. If necessary or desired, those
adhesive materials or other adhesive materials may be used after
the application of a board primer. An acceptable board primer may
be Royal 20069 brand primer, which is also available from Royal
Adhesives and Sealants LLC.
[0065] In one example, the adhesive material 56 is a soluble
adhesive (e.g., a water-soluble adhesive), so that the tray 70
(FIG. 3), or the like, may be recycled by placing it in a bath that
includes the appropriate solvent (e.g., water) and optionally
agitating, heating and/or otherwise processing the bath to separate
the paperboard 52 and polymer film 50/web 54. In one specific
example in which the adhesive material 56 is a soluble adhesive,
such as a water-soluble adhesive, the separating may occur in a
paper recycling plant, where the polymer film 50/web 54/polymeric
material may be separated from the paperboard 52/pulp by way of a
bath that contains water and is processed in a suitable manner. The
separated polymer film 50/web 54/polymeric material may be burned
as fuel, such as in the paper recycling plant, or otherwise be
recycled.
[0066] Whereas a few specific examples of acceptable methods for
forming the laminates 20, 20' are discussed above, those of
ordinary skill will understand that there are a variety of ways in
which the laminates can be constructed. That is, the layers of the
laminates 20, 20' can be joined using any suitable process or
technique. By way of example, and not limitation, the layers may be
joined using adhesive bonding, thermal bonding, or any other
chemical or mechanical means. Bonding may be achieved using any
suitable process, for example, spraying, roll coating, extrusion
lamination, or any other process.
[0067] As alluded to above, the blank 22 can be configured to be
part of a container or other type of construct, such as the tray 70
shown in FIG. 3. In accordance with the first embodiment, the tray
70 is at least substantially leakproof/hermetically sealed.
Therefore, it is typical for each of the fold lines 28, 32, 38 to
be a score line that does not form a hole in the blank 22/laminate
20. In accordance with alternative embodiments of the present
invention, the fold lines 28, 32, 38 can be formed in any
conventional manner, and one or more of them can be omitted.
[0068] As best understood with reference to FIG. 3, the tray 70 of
the first embodiment includes the blank 22 and a frame 72 that
holds the blank in an erected configuration. The frame 72 is
typically constructed of polymeric material; however, the frame can
also be constructed of other types of materials. Referring also to
FIG. 4, which schematically shows the frame 72 in isolation, the
frame 72 includes strip-like corner elements 74 that extend
downwardly and somewhat inwardly (obliquely, or more specifically
acutely) from a substantially rigid band 76 of the frame 72. In
accordance with the first embodiment, the corner elements 74
advantageously hermetically seal the corners of the tray 70, as
will be discussed in greater detail below.
[0069] As best understood with reference to FIG. 3, the panels 24,
30, 26 (FIG. 1A) of the blank 22 (FIG. 1A) and the strip-like
corner elements 74 of the frame 72 together extend around and
define a substantially leakproof cavity 78 of the tray 70.
Typically the polymer film 50 (FIGS. 2A and 2B) of the blank is
fluid impervious and in opposing face-to-face relation with the
cavity 78. The base panel 24 of the tray 70 optionally includes an
embossed area 80 that is partially defined by a score-like line 82
in the base panel 24. The embossed area 80 of the base panel 24
protrudes slightly into the cavity 78 of the tray 70, and it can
help to rigidify the tray.
[0070] FIG. 5 is a schematic cross-sectional view of the tray 70
taken along line 5-5 of FIG. 3, with only the cross-section being
shown. As best understood by referring also to FIG. 3, the tray 70
typically includes a multi-tiered rim 84. The rim 84 extends around
and defines an opening to the cavity 78 of the tray 70. In
accordance with the first embodiment, the upper portion of the rim
84 is defined by the band 76 of the frame 72, and the lower portion
of the rim 84 is defined by the flange portions 34a-34d of the
blank 22. As best understood with referenced to FIG. 5, the two
tiers of the rim 84 are partially defined by an upright panel or
section 85 of each of the flange portions 34a-34d of the blank. A
lower flange 81 extends outwardly from the upper edge of the
respective side panel 30 to the lower edge of the upright section
85. An upper flange 83 extends outwardly from an upper edge of the
upright panel or section 85. All or some of the upper flange 83 can
be omitted. Each upright section 85 includes an upright inner
shoulder 92. As will be discussed in greater detail below, the band
76 is typically adhered to the upper surfaces of the flanges 81, 83
and the inner shoulder 92, so that the band includes a flat upper
surface positioned above the upper surfaces of the flanges 81, 83,
and a cover, lid or the like can be sealed to the upper surface of
the band. As will also be discussed in greater detail below,
typically the band 76 is thicker above the lower flange 81 than it
is above the upper flange 83, such that the lower flange
advantageously partially defines a relatively large channel for
having molding material (e.g., fluid polymeric material) flow
therein during the injection molding.
[0071] FIG. 5 is illustrative of numerous vertical cross sections
of the tray 70. More specifically, FIG. 5 is illustrative
of/representative of vertical cross-sections taken through each of
the side panels 30 and associated portion of the multi-tiered rim
84. On the other hand, other cross-sectional profiles are also
within the scope of the present invention. For example, the flange
portions 34a-34d of the blank can be shaped and/or sized
differently, so that the flange portions 34a-34d do not extend all
the way to the outer edge of the rim 84 of the tray 70, or so that
the flange portions 34a-34d are embedded in the band 76 of the
frame 72. As another example, the flange portions 34a-34d of the
blank 22, or the like, can extend farther outwardly than the band
76 of the frame 72, and the rim 84 can consist substantially solely
of the flange portions 34a-34d.
[0072] As best understood with reference to FIG. 3, the band 76 of
the frame 72 can optionally include a minor imperfection 86 and pin
holes 88. The minor imperfection 86 and the pin holes 88 result
from an exemplary process by which the tray 70 is manufactured.
However, the minor imperfection 86 and the pin holes 88 are
optional features because it may be possible to manufacture the
tray 70 without forming the minor imperfection 86 and the pin holes
88. Indeed, in one example of the present invention, the pins that
form the pin holes 88 are omitted, as will be discussed in greater
detail below. Also and as will be discussed in greater detail
below, the frame 72 can be injection molded using a valve gate so
that any imperfection 86 is minimized. Alternatively, even if the
minor imperfection 86 and the pin holes 88 are formed, steps may be
taken so that the they are removed or otherwise not readily
visible.
[0073] An acceptable method for manufacturing the tray 70 will be
discussed in greater detail below (e.g., with reference to the mold
assembly 130 shown in FIG. 8A). Nonetheless, some aspects
associated with an exemplary method of manufacturing the tray 70
are illustrated in FIG. 3 and will, therefore, now be briefly
discussed with reference to FIG. 3. The minor imperfection 86
results from the frame 72 being manufactured from molding material,
namely polymeric material, that is injected into a mold. That is,
the imperfection 86 is located at the sole location where the
liquid molding material is injected (e.g., via a valve gate). The
arrows drawn onto the frame 72 in FIG. 3 schematically illustrate
the directions in which some of the fluid molding material flows to
form the frame 72. The arrows drawn onto the frame 72 in FIG. 3 are
schematic because they would not be seen on a formed tray 70.
[0074] In accordance with the first embodiment and referring to
FIG. 5, flow of the fluid molding material is controlled in a
manner that seeks to keep the band 76 of the frame 72 on top of the
flange portions 34 of the blank 22. More specifically, end edges of
the flange portions 34a-34d (FIG. 1A), namely the protruding
features 44a-44h (e.g., see the protruding features 44a, 44b
identified in FIG. 1B), are respectively overlapped and at least
some of the flange portions are optionally held in a predetermined
manner by pins (e.g., see pins 144 shown in FIGS. 8A and 11B) that
respectively cause the pin holes 88 to be formed, so that the fluid
molding material flows over the flange portions 34a-34d during
injection molding, as will be discussed in greater detail below.
Even more specifically and as best understood by referring to FIGS.
1A and 3, the flange portions 34a-34d respectively include
overlapping end edges 90a, 90b, 90c, 90d (which are hidden from
view by the band 76 in FIG. 3 and, therefore, illustrated by dashed
lines in FIG. 3). In the tray 70 shown in FIG. 3, the end edge 90a
of the flange portion 34a overlaps the adjacent end of the flange
portion 34b, so that the end edge 90e of the flange portion 34b is
below the flange portion 34a. Similarly, the end edge 90b of the
flange portion 34a overlaps the adjacent end of the flange portion
34c. Likewise, the end edge 90c of the flange portion 34b overlaps
the adjacent end of the flange portion 34d. Lastly, the end edge
90d of the flange portion 34c overlaps the adjacent end of the
flange portion 34d.
[0075] In accordance with other embodiments of the present
invention, different techniques can be used to form the band 76 of
the frame 72 on top of the flange portions 34 of the blank 22. As
one example, the above and below discussed pinning of the
overlapping end edges 90a-90d can be omitted, and the frame 72 can
be formed by injecting the fluid molding material into the main
cavity of the mold assembly (e.g., mold assembly 130 of FIG. 8A) at
multiple locations. In contrast and in accordance with other
alternative embodiments of the present invention, the band 76 of
the frame is not formed on top of the flange portions 34a-34d of
the blank 22. For example, the flange portions 34a-34d can be
embedded within the band 76 or be positioned above the band.
[0076] FIG. 6 schematically shows the outer side of a
representative corner of the tray 70, as viewed generally from
below. In accordance with the first embodiment, the corner includes
an outwardly protruding bulbous portion 100 that is located at the
lower end of the corner. Also, a relatively small gap 102, which is
defined between the edges of the side panels 30 that partially
define the corner, extends upwardly from the bulbous portion 100.
At the lower end of each corner of the tray 70, outer surfaces of
the side panels 30 and intermediate panels 26 define an outwardly
curved surface of the bulbous portion 100, and the corresponding
inner surfaces of the side panels 30 and intermediate panels 26
define a substantially bowl-shaped recess 101 shown in FIG. 7B.
[0077] FIG. 7A illustrates the inner side of the representative
corner illustrated in FIG. 6, with an upper part of the tray 70 cut
away and an additional upper portion of the strip-like corner
element 74 of the frame 72 cut away. FIG. 7B is like FIG. 7A,
except that the corner element 74 of the frame 72 has been removed.
As best understood with reference to FIG. 7A, the strip-like corner
element 74 of the frame 72 can be characterized as being, or
including, a strip that extends along and at least partially
defines the corner of the tray 70, with this strip obstructing the
gap 102. Referring to FIG. 6 and in accordance with the first
embodiment, a majority of the outer side of the corner is defined
by the paperboard 52 of the blank 22, except that a bead 106 (e.g.,
an elongate, outwardly projecting protrusion) of the associated
strip-like corner element 74 of the frame 72 protrudes into and
fills (e.g., hermetically seals) the gap 102. Similarly and as
shown in FIG. 6, all of the lower surface of the rim 84 is defined
by paperboard 52 of the blank 22. Nonetheless, differently
configured corners and rims are within the scope of the present
invention. For example, the lower surface of the rim 84 can be
partially in the form of the band 76 (FIG. 3), as will be discussed
in greater detail below.
[0078] As best understood with reference to FIG. 6, outwardly
projecting ribs 104 extend upwardly form the bulbous portion 100
and are positioned on opposite sides of the gap 102. For each
corner of the tray 70, its bead 106 is collinear with the corner's
elongate centerline that extends along the corners' length, and the
bead is spaced apart from (e.g., centered between) the corner's
ribs 104. As shown in FIG. 6, the ribs 104 comprise curved portions
of the panels 30. The outward surface of each rib 104 is an
outwardly projecting, convex protrusion of the respective panel 30,
with the outwardly projecting protrusion of the panel being
elongate and extending along the respective corner of the tray 70.
In accordance with the first embodiment, these outwardly projecting
protrusions of the panels 30/ribs 104 are not pleats.
[0079] As best understood with reference to FIG. 7B, for each rib
104, the inward surface of the associated curved portion of the
panel 30 defines a recess 108 that is elongate and extends along
the corner of the tray 70. In addition and as best understood with
reference to FIG. 7A, each rib 104 further includes a portion of
the respective strip-like corner element 74 of the frame 72, namely
an outwardly projecting, convex protrusion 110 that is elongate,
extends along the corner, and extends into the respective recess
108 of the curved portion of the respective panel 30.
[0080] As best understood with reference to FIG. 3 and primarily
with reference to FIG. 7A, for each interior corner of the tray 70,
from top to bottom, the inner side of the corner is smoothly
rounded from side to side. The strip-like corner element 74 of the
frame 72 that extends into the corner includes an inwardly facing,
smooth surface that can be characterized as having an upper portion
120 and a lower portion 122. The corner element 74 is shaped to
contribute to the smooth side-to-side curvature of the inner side
of the corner of the tray 70. More specifically, the upper portion
120 (of the inwardly facing surface of the strip-like corner
element 74) extends concavely and smoothly between the adjacent
side panels 30, and all the way up to the rim 84. The lower portion
122 (of the inwardly facing surface of the corner element 74)
extends smoothly and in somewhat of a concave/bowl-like fashion
between the adjacent intermediate panels 26.
[0081] The exemplary manner in which the corners of the tray 70 are
constructed is advantageous because it avoids pleating, or the
like, of the blank 22. The avoidance of the pleating, or the like,
and the sealing of the relatively small gap 102 (FIGS. 6, 7A and
7B) can play an advantageous role with respect to the tray 70 being
hermetically sealed and, therefore, leakproof. More specifically,
the outwardly bulbous portion 100 (FIG. 6) in combination of the
outwardly projection ribs 104 (FIG. 6) helps to provide a
pleat-free corner with a smoothly-radiused interior surface,
without there being an undercut. This lack of an undercut allows
the tray 70 to be easily removed from the mold (e.g., mold assembly
130 of FIG. 8A) in which it is formed, as will be discussed in
greater detail below. As an example of an additional advantage that
is discussed in greater detail below, the outwardly bulbous portion
100 and the outwardly projection ribs 104 help to define relatively
large channels for accommodating flowing molding material during
the injection molding. Notwithstanding the foregoing, other
configurations of the corners and other features are also within
the scope of the present invention, and in some applications the
tray 70 may not need to be, and therefore may not be, constructed
to be leakproof.
[0082] FIG. 8A schematically illustrates a forming tool (e.g., mold
assembly 130) that can be used in the manufacture of the tray 70,
in accordance with the first embodiment. The mold assembly 130 is
in an open configuration in FIG. 8A, and it includes a male mold
132 and a female mold 134. The male mold 132 includes an outer mold
136 to which a nose unit 138 is movably mounted. A group of springs
140, only two of which are schematically shown in FIG. 8A, urge the
nose unit 130 toward the female mold 134. The nose unit 138
typically includes one or more flushly mounted vacuum cups 142 that
are open at the face of the nose unit 138. The one or more vacuum
cups 142 are connected to a suction source (not shown) so that a
suction can be supplied to the vacuum cups 142 in a controlled
manner, as will be discussed in greater detail below. Optionally,
four securing elements, such as securing pins 144, protrude from
the male outer mold 136 for aiding in the forming of the tray 70,
as mentioned above and as will also be discussed below. There can
be a greater or lesser number of securing elements (e.g., securing
pins 144), and in some situations they can be completely
omitted.
[0083] A port 146 (e.g., with a valve gate) is defined in the male
outer mold 136, or otherwise provided, for injecting fluid molding
material, or the like, into the mold assembly 130 to form the frame
72. In one example, the port 146 is in the form of, or includes, a
valve gate. More specifically, a valve stem is moved to open and
close the port 146 in a manner that seeks to minimize shearing of
solidified molding material at the imperfection 86 (FIG. 3) caused
by the port 146. This can advantageously aid in the formation of a
smooth surface on the band 76 of the frame 72.
[0084] The female mold 134 includes an outer mold 150 to which an
embossing unit 152 is movably mounted. A group of springs 154, only
two of which are schematically shown in FIG. 8A, urge the embossing
unit 152 toward the male mold 132. A group of locating pins 156 are
typically mounted to the female outer mold 150 in an arrangement
that is for helping to position the blank 22 in a predetermined
location, as will be discussed in greater detail below. The flat
blank 22 is schematically illustrated by dashed lines in FIG. 8A.
The embossing unit 152 typically includes one or more flushly
mounted vacuum cups 158 that are open at the face of the embossing
unit 152. The one or more vacuum cups 158 are connected to a
suction source (not shown) so that a suction can be supplied to the
vacuum cups 158 in a controlled manner, as will be discussed in
greater detail below.
[0085] The shapes of the surfaces of the female outer mold 150 that
define the main cavity of the female outer mold 150 and the face of
the embossing unit 152 respectively correspond to the shapes of the
exterior surfaces of the tray 70. As shown in FIG. 9, the female
outer mold 150 includes interior corners that are positioned in the
main cavity of the female outer mold 150. Each of these interior
corners includes a subcavity 160 that is at least partially in the
form of a concavity. The subcavities 160 are respectively proximate
the corners of the centrally open base 161 of the female outer mold
150. The central opening of the base 161 is for being in receipt of
the embossing unit 152 (e.g., see FIG. 8A). The subcavities 160 are
bowl-shaped recesses that partially define the main cavity of the
female outer mold 150 and the interior corners of the female outer
mold 150. The subcavities 160 are for at least partially forming
the outwardly bulbous portions 100 (FIG. 6) of the corners of the
tray 70.
[0086] Each of the interior corners in the main cavity of the
female outer mold 150 also includes a pair of spaced apart,
elongate indentions 162 that respectively extend from the
subcavities 160 all the way to the tiered shoulder 164 of the
female outer mold 150. The shoulder 164 extends all the way around
the main cavity of the female outer mold 150, and can be
characterized as defining the opening to the main cavity of the
female outer mold 150. The shoulder 164 is tiered/has a series of
step-like surfaces for at least partially forming the lower surface
of the rim 84 (e.g., see FIG. 5) of the tray 70; more specifically
for at least partially forming (e.g., at least partially
controlling folding of) the lower flange 81, upper flange 83 and
upright section 85 of the rim 84. The elongate indentions 162 are
for at least partially forming the outwardly projecting ribs 104
(FIG. 6) of the corners of the tray 70. Between each pair of
elongate indentions 162 is an elongate central region 166 that
projects into the main cavity of the female outer mold 150. The
elongate central regions 166 respectively extend from the
subcavities 160 all the way to the shoulder 164 of the female outer
mold 150. The central regions 166 are respectively for at least
partially forming the centerlines of the corners of the tray 70.
Differently shaped corners within the main cavity of the female
outer mold 150 are also within the scope of the present
invention.
[0087] An exemplary method of forming the tray 70 using the mold
assembly 130 and the blank 22 is described in the following. As
best understood with reference to FIGS. 8A and 9, in an initial
step, the flat blank 22 (shown by dashed lines in FIGS. 8A and 9)
is placed against the female mold 134 so that the locating pins 156
are arranged around, and engage, the periphery of the blank 22.
That is, the locating pins 156 help to facilitate proper placement
of the blank 22. The blank 22 is held in this proper placement by
virtue of the embossing unit 152 being in its outward
configuration, and suction being supplied to the vacuum cups 158,
so that the vacuum cups hold the blank. As a result, the blank 22
is securely held against the face of the embossing unit 152, as is
partially schematically illustrated by the dashed-line showing of
the flat blank 22 in FIG. 8A.
[0088] While the blank 22 is being held in place against the face
of the embossing unit 152 as a result of suction being supplied to
the vacuum cups 158, the entire female mold 134 is advanced toward
the stationary outer mold 136 of the male mold 132 under the action
of a hydraulic press (not shown), or the like. Alternatively, the
male mold 132 could be moved toward the female mold 134. As the
flat blank 22 comes into contact with the nose 138, the base panel
24 of the blank 22 is sandwiched between the face of the nose 138
and the face of the embossing unit 152, and the springs 140, 154
compress. The face of the nose 138 and the face of the embossing
unit 152 are typically cooperatively shaped so that sandwiching of
the blank 22 between the nose 138 and the embossing unit 152 causes
the embossed area 80 (FIGS. 3 and 5) to at least eventually be
formed in the base panel 24 of the blank 22. As the mold assembly
130 further closes, the base panel 24 is securely held between the
nose 138 and the embossing unit 152, and interaction between the
blank 22 and the mold assembly 130 causes folding to occur along
the fold lines 28, 32, 38 of the blank so that the blank becomes
erected. As a result, the blank 22 is in an erected state within
the main cavity of the mold assembly 130 when the mold assembly
achieves the fully closed configuration schematically illustrated
in FIG. 10A.
[0089] Prior to the mold assembly reaching the closed configuration
shown in FIG. 10A, while the mold assembly 130 is still closing,
the differences between the lengths of the protruding features
44a-44h (FIGS. 1A and 1B) can be utilized to facilitate the desired
overlapping of the end edges of the flange portions 34a-34d, which
was discussed above with reference to FIG. 3.
[0090] FIG. 10B is a schematic, isolated top plan view of a portion
of a representative corner of the blank 22 with side panels 30
folded upwardly. FIG. 10B illustrates an intermediate step of the
blank 22 being erected by closing the blank in the mold assembly
130. FIG. 10B is representative of the blank 22 having been
partially forced into the cavity of the female outer mold 150. As
shown in FIG. 10B, since the protruding feature 44f is longer than
the protruding feature 44b, the protruding feature 44f extends
farther outwardly than the protruding feature 44b. That is, when
the blank 22 has been partially forced into the cavity of the
female outer mold 150 to the degree schematically shown in FIG.
10B, the longer protruding features 44e, 44f, 44g, 44h protrude
farther outwardly than the shorter protruding features 44a, 44b,
44c, 44d.
[0091] FIG. 10C is like FIG. 10B, except that the blank 22 is
schematically shown as having been farther forced into the cavity
of the female outer mold 150, so that the longer protruding feature
44f is being abutted by the shoulder 164 of the female outer mold
150 (the shoulder 164 is shown in greater detail in FIGS. 8A, 8B
and 9). The shoulder causes the longer protruding feature 44f to
move (e.g., fold) into superposed relationship with the shorter
protruding feature 44b. That is, while the mold assembly 130 is
closing, because of their greater length, the longer protruding
features 44e, 44f, 44g, 44h engage the shoulder 164 of the female
outer mold 150 before the shorter protruding features 44a, 44b,
44c, 44d can engage the shoulder 164. As a result, the longer
protruding features 44e, 44f, 44g, 44h respectively move (e.g.,
fold) into superposed relationships with the shorter protruding
features 44a, 44b, 44c, 44d, so that the shorter protruding
features 44a, 44b, 44c, 44d are respectively positioned between the
longer protruding features 44e, 44f, 44g, 44h and the female outer
mold 150. As a result, when the resulting tray 70 is viewed from
above, the shorter protruding features 44a, 44b, 44c, 44d
respectively overlap the longer protruding features 44e, 44f, 44g,
44h, as schematically illustrated in FIG. 3 by the broken-line
showing of the overlapping end edges 90a, 90b, 90c, 90d of the
shorter protruding features 44a, 44b, 44c, 44d of the flange
portions 34a-34d.
[0092] As best understood with reference also to FIG. 8A, in the
configuration illustrated by FIG. 10C, the female mold 134 has been
advanced so that the mold assembly 130 is in the fully closed
configuration shown in FIG. 10A, except that the male outer mold
136 is still extended from the nose unit 138 so that male outer
mold 136 does not interfere with the above-discussed folding of the
longer protruding features 44e, 44f, 44g, 44h. That is and in
accordance with the first embodiment, the embossing unit 152
achieves its retracted configuration (shown in FIG. 10A) with
respect to the female outer mold 150 before the nose unit 138
achieves its retracted configuration (shown in FIG. 10A) with
respect to the male outer mold 136. This difference can be achieved
by having the group of springs 140 of the male mold 132 being
stronger than the group of springs 154 of the female mold 134.
[0093] After the configuration schematically illustrated by FIG.
10C, the mold assembly 134 is fully closed so that the flange
portions 34a-34e (FIG. 1) are partially folded, such as by at least
partially being bent/folded along the outer fold lines 36 (FIG. 1).
In the fully closed configuration of the mold assembly 130 shown in
FIG. 10A, channels (e.g., see FIGS. 11A, 11B and 13), which are for
having a molding material (e.g., fluid polymeric material) flow
therein, are defined within the mold assembly. The channels, which
are for having the molding material flow therein are discussed in
the following, in accordance with the first embodiment. These
channels are at least primarily defined between the partially
erected blank 22 and the male mold 132. These channels at least
generally correspond to the shape of the frame 72, although at
least some of the channels expand during the injection molding due
to movement of respective portions of the blank 22 while the
molding material flows within the channels. More specifically and
for example, as fluid molding material (e.g., fluid polymeric
material) is forced under pressure into initial channels, at least
some of the initial channels expand and are transformed into
resultant channels due to movement of respective portions of the
blank 22 while the fluid molding material flows within the
channels. This includes liquid molding material flowing with
sufficient force to cause portions of the blank 22 to be pressed
against respective surfaces of the female mold 134 (e.g., FIG. 9),
so that respective parts of the blank are forced against the
shoulder 164, and into the subcavities 160 and elongate
indentations 162.
[0094] In one example, the liquid molding material is a polymer
that is injected into the closed mold assembly 130 via the port
146, with the injected polymer being at a temperature of about 500
degrees Fahrenheit and a pressure of approximately 2000
lb/in.sup.2. The injection temperature and pressure may depend upon
the polymer that is injected, and a wide variety of polymers,
temperatures and pressures are within the scope of the present
invention. For example and not for the purpose of limiting the
scope of the present invention, suitable polymers for being
injected may be polypropylene, nylon and polyethylene terephthalate
(PET). In one example, the liquid molding material is polypropylene
that is injected into the closed mold assembly 130 via the port
146, with the injected polypropylene being at a temperature of
about 450 degrees Fahrenheit and a pressure of approximately 1750
lb/in.sup.2. The polymeric liquid molding material that is injected
into the closed mold assembly 130 via the port 146 may include one
or more additives, such as short glass fibers. Impregnating the
polymeric liquid molding material with short glass fibers can help
to advantageously control/minimize shrinkage of the solidifying
polymeric material. The polymeric liquid molding material may
include about 30% glass fibers by weight, although other amounts
and other additives are also within the scope of the present
invention.
[0095] More specifically, the flange portions 34a-34c (FIG. 1A) are
typically only partially folded during closing of the mold assembly
130, such that the flowing molding material in the mold assembly
130 at least completes the forming and/or bending and/or folding of
the flange portions (e.g., by pressing them against the female
mold's shoulder 164) that is necessary to provide the multi-tiered
rim 84 (FIG. 5). Similarly, when the mold assembly 130 is closed
and prior to the injecting of the molding material, the recesses
101, 108 (e.g., FIG. 7B) in the blank are not yet formed or are
only partially formed, such that the flowing molding material in
the mold assembly 130 at least completes the forming and/or bending
and/or folding that creates the recesses 101, 108, by pressing the
respective portions of the blank into the female mold's subcavities
160 (FIG. 9) and elongate indentations 162 (FIG. 9).
[0096] Stated different and in accordance with one example of the
first embodiment, in each interior corner of the female outer mold
150, the elongate indentations 162 advantageously receive
respective portions of the blank 22 and thereby help to define
relatively large channels for accommodating the flow of molding
material. These relatively large channels seek to help keep the
fluid molding material in predetermined areas, namely it causes the
strip-like corner elements 74 of the frame 72 to be formed, for the
most part, within the cavity 78 of the tray 70. As best understood
with reference to FIGS. 6 and 7A, these relatively large channels
respectively correspond to the elongate, relatively thick portions
of the frame's corner elements 74 that are respectively part of the
outwardly projecting ribs 104.
[0097] Stated different and in accordance with another example of
the first embodiment, the forceful flowing of the molding material
can also force at least portions of the flange potions 34a-34d of
the blank 22 against respective portions of the shoulder 164 of the
female mold 134. That is, as the polymeric fluid flows in the
channels, it pushes respective portions of the paperboard 52, or
the like, of the blank 22 into intimate contact with respective
portions of the female mold 134.
[0098] For example, and as can be best understood also with
reference to FIGS. 1B and 10C, FIG. 11A schematically illustrates,
by way of an arrow, the injected molding material flowing in a
downstream direction through a representative channel at an upper
interior corner of the mold assembly 130. As shown in FIG. 11A, the
channel is defined between the shoulder 164 (which is part of the
female outer mold 150) and the male outer mold 136. The protruding
features 44f, 44b can be characterized as being within the channel,
or the channel can alternatively be characterized as being defined
between the protruding features 44f, 44b and the male outer mold
136. The protruding features 44f, 44b are overlapped, and the edge
90b of the shorter protruding feature 44b is positioned between the
longer protruding feature 44f and the channel. With respect to the
portion of the channel shown in FIG. 11A, as the injected molding
material flows through the upstream portion of the channel it
forces the shorter protruding feature 44b against the shoulder 164.
The flow of the molding material through the intermediate portion
of the channel forces the end section of the shorter protruding
feature 44b against the end section of the longer protruding
feature 44f, which advantageously seeks to keep the flowing molding
material from lifting the edge 90b in a manner that might allow the
molding material to flow on the wrong side of the flange portions
34a-34d of the blank 22. A securing pin 144 (FIGS. 8A and 11B) is
not shown in the channel of FIG. 11A because, for example, the
securing pins 144 can be omitted.
[0099] As best understood with reference to FIGS. 1 and 3 and the
portion of the representative corner schematically shown in FIG.
11B, the securing pins 144 (which are optional and may be omitted)
are respectively proximate, yet distant from the end edges 90a-90d.
The securing pins 144 may respectively engage and hold the flange
portions 34b-34d of the blank 22 against the shoulder 164 of the
female outer mold 150 to help define the channels in which the
fluid molding material flows, and to maintain the proper
positioning of the molding material (i.e., frame 72) with respect
to the blank 22. From the perspective of the flowing molding
material, for each pair of closely adjacent end edges of the flange
portions 34a-34d, typically only the downstream flange portion is
pinned down by a securing pin 144. That is, typically the securing
pins 144 engage only the flange portions 34b-34d at positions
adjacent to the longer protruding features 44e, 44f, 44g, 44h.
Depending, for example, upon the pressure at which the fluid
molding material is injected and/or the number of, or location of,
the injection ports (e.g., see the port 146 in FIG. 8A) at which
the fluid molding material is injected and/or the overlapping
between the protruding features 44a-44h, the securing pins 144 can
be omitted. Typically the securing pins 144 will be omitted, since
they can cause imperfections and/or cause the tray 70 to stick to
the male mold 132. That is, variously configured mold assemblies
130, trays 70 and other features are within the scope of the
present invention.
[0100] More specifically regarding the channels in which the
frame's band 76 of the first embodiment is formed, there is a
relatively large inner channel and a relatively small outer
channel. As can be best understood with reference to FIG. 5, the
portion of the band 76 that is to the right of an imaginary
vertical line that extends along the shoulder 92 and to the top of
the band 76 corresponds to the relatively large inner channel, and
the remainder of the band 76 corresponds to the relatively small
outer channel. During the injection molding, the fluid molding
material primarily flows along the relatively large inner channel,
and flows from the relatively large inner channel outwardly to the
relatively small outer channel. This outwardly flowing seeks to
help keep the molding material in predetermined areas, namely it
helps to force the flange portions 34a-34d against the shoulder 164
of the female outer mold 150 in a manner that seeks to prevent the
flange portions 34a-34d from folding in the wrong direction (not
shown).
[0101] As best understood with reference to FIG. 11B, the tips of
the securing pins 144 extend into the relatively large outer
channel. As can be best understood with reference to FIG. 6, the
upright section 85 of the flange portions 34a-34d is closer to the
outer edge of the rim 84 in the corners of the tray 70, so that the
width of the relatively large inner channel is larger in the
corners of the tray 70 than elsewhere. This allows for the tips of
any securing pins 144 to extend into the relatively large inner
channel at the corners of the tray 70 without unduly restricting
the flow of the fluid molding material. Also so as not to unduly
interfere with the flow, the tips of the securing pins 144 are
positioned closer to the outer side of the relatively large inner
channel, as shown in FIG. 11B.
[0102] After the liquid molding material solidifies so that the
tray 70 is formed within the mold assembly 130, the mold assembly
is opened. While the mold assembly is being opened, suction is
supplied to the vacuum cups 142 of the male mold 132, and not to
the vacuum cups 158 of the female mold 134, so that the formed tray
70 is held by suction to the nose 138 of the male mold 132. The
tray 70 can be readily removed upon cessation of the suction.
Thereafter, the mold assembly 130 can be used to manufacture
another tray 70.
[0103] As mentioned above, the corners of the tray 70 are typically
constructed in a manner that seeks to make the tray leakproof. In
addition, the corners are typically formed so that the tray 70 does
not include an undercut that inhibits the tray 70 from being
removed from the mold assembly 130. Notwithstanding the foregoing,
other configurations of the corners and tray 70 are also within the
scope of the present invention. For example, the tray 70 could be
modified so that it is not leakproof, for applications that do not
require leakproofness.
[0104] In accordance with the first embodiment, the film 50 of the
laminate 20/blank 22 and the molding material (e.g., polymeric
material) from which the frame 72 are constructed are selected to
be compatible, so that there is good adhesion between the frame 72
and the film 50 of the blank 22. In one example, both the frame 72
and the film 50 are a polyolefin, such as polypropylene. As another
example, each of the frame 72 and the film 50 can be nylon or
polyethylene terephthalate. A wide variety of other polymers can
also be used, as discussed in greater detail below. When the film
50 is a coextrusion, it is the outer-most layer of the film 50 that
is selected to be compatible with the frame 72 so that there is
good adhesion therebetween. In an alternative embodiment of the
present invention, such as where the materials are selected so that
there is less adhesion between them (i.e., less adhesion between
the flame 72 and the blank 22), the blank or portions thereof
(e.g., edges of the blank) can be at least partially embedded in,
or encapsulated by, the frame in a manner such that the blank and
the frame are nonetheless fixedly attached to one another, if
desired.
[0105] Initially forming the blank 22 with the fold lines 28, 32,
38, which can be score lines, seeks to aid in the erecting of the
blank within the closing mold assembly 130. However, one or more of
the score lines (e.g., fold lines 28, 32, 38) could be omitted from
the blank 22, in which case it may be necessary to close the mold
assembly relatively slowly, in an effort to ensure that the blank
is properly erected therein. For example, the flat blank 22
schematically shown in FIGS. 8A and 9 could completely lack
fold/score lines. That is, a variety of different blanks are within
the scope the scope of the present invention. Likewise, a variety
of different mold assemblies are within the scope of the present
invention. Therefore, a variety of different constructs (e.g.,
blanks, trays, cartons and other containers) are also within the
scope of the present invention.
[0106] In accordance with the first embodiment, after the tray 70
is formed, food can be placed in the tray's cavity, and then the
tray's opening can be closed in a leakproof manner, such as with a
cover in the form of a polymeric overwrap that can be
advantageously heat sealed to the flat upper surface of the band 76
of the frame 72. For example, FIG. 12 schematically illustrates the
tray 70 of FIG. 3 containing food 170 and closed with a polymer
film 172 that is heat sealed to the substantially flat, upwardly
facing surface of the band 76 of the frame 72. FIG. 12 is schematic
because the food 170, which is hidden from view, is shown by dashed
lines, and the thickness of the overwrap/polymer film 172 that
closes the tray 70 is exaggerated. Alternatively, the tray 70 can
be closed with lids made of paperboard, foil or any other suitable
material. A variety of mechanisms for closing the opening of the
tray 70, such as in a leakproof manner, are within the scope of the
present invention.
[0107] Referring back to FIG. 11B, it schematically illustrates a
line of engagement 180 that exists between the outer mold 136 and
nose unit 138 of the male mold 132. The line of engagement 180 may
in some situations result in the formation of parting lines (not
shown) in the corner elements 74 of the polymeric frame 72, with
the parting lines corresponding with/being in opposing face-to-face
contact with the respective portions of the line of engagement 180
while the mold assembly 130 is closed. The parting lines are
optional and may be omitted.
[0108] FIG. 13 schematically illustrates a line of engagement 380
that exists between an outer mold 336 and nose unit 338 of a male
mold 332 of a second exemplary embodiment of the present invention.
The second embodiment is like the first embodiment, except for
variations noted and variations that will be apparent to those of
ordinary skill in the art. Therefore, reference characters for
elements of the second embodiment that are at least generally like
elements of the first embodiment are the same, except that they are
incremented by two hundred.
[0109] FIG. 13 is like FIG. 11B, except, for example, that in FIG.
13 an entire length of the representative corner element 274 of the
polymeric frame 272 is shown, and the male mold 332 of the second
embodiment has been substituted so that the line of engagement 380
between the male outer mold 336 and the nose unit 338 is located in
a manner that seeks to prevent formation of a parting line in the
corner element 274. That is, the line of engagement 380 between the
male outer mold 336 and the nose unit 338 typically will not cause
a parting line in the corner elements 274 of the polymeric frame
272 of the second embodiment. Also, the securing pin 144 has been
omitted from FIG. 13, for example since the securing pins 144 are
optional and may typically be omitted. Alternatively, the securing
pins could be included in the second embodiment.
[0110] FIG. 13 illustrates the fully closed mold assembly 330, in
accordance with the second embodiment. In this fully closed
configuration of the second embodiment: the male mold 332 extends
into the cavity of the female mold 334; the lines of engagement 380
between the male outer mold 336 and the nose unit 338 of the male
mold are distant from all parts of the polymeric frame 272 in a
manner that seeks to avoid the formation of parting lines; the nose
unit 338 of the male mold is in a retracted configuration with
respect to the male outer mold 336; and the embossing unit 352 of
the female mold 334 is in a retracted configuration with respect to
the female outer mold 350.
[0111] FIG. 14 is an isolated pictorial view of the male outer mold
336 in accordance with the second embodiment. The male outer mold
336 includes a central cavity 336a, corners 336b, and projections
336c that extends the corners.
[0112] FIG. 15 is an isolated pictorial view of the nose unit 338
(e.g., inner mold) of the male mold 332 in accordance with the
second embodiment. The nose unit 338 includes corners with recesses
338a for respectively being in receipt of the projections 336c of
the male outer mold 336 during the retracted configuration.
[0113] As with the first embodiment, the nose unit 338 of the
second embodiment is movably mounted to the male outer mold 336 for
moving between an extended configuration and a retracted
configuration. Exemplary aspects of the mold assembly 330 of the
second embodiment being in its closed configuration, which is shown
in FIG. 13 and includes the nose unit 338 being in its retracted
configuration, are described in the following. The nose unit 338 is
at least partially within the cavity 336a of the male outer mold
336 so that the projections 336c of the male outer mold 336 are
respectively positioned in the recessed corners 338a of the nose
unit 338, so that the projections 336c extend at least partially
around the nose unit 338. As a result, the corners 336b/projections
336c of the male outer mold 336 are respectively positioned between
the nose unit 338 and the interior corners of the female outer mold
350 (e.g., see FIG. 9, which shows that each of the interior
corners of the female outer mold 150 includes a central region 166
between elongate indentations 162). As best understood with
reference to FIG. 13, the channels, which are for having the
molding material (e.g., fluid polymeric material) flow therein
during the forming of the corner elements 274 of the polymeric
frame 272 are therefore defined solely between the corners
336b/projections 336c of the male outer mold 336 and the interior
corners of the outer mold 350 (i.e., between the corners
336b/projections 336c and those portions of the blank 22 that are
in the interior corners of the outer mold 350). In FIG. 13, the
representative corner element 274 that is shown is schematically
representative of one of the injection-molding channels that is
defined between the corners 336b/projections 336c and the portion
of the blank 22 in the respective interior corner of the outer mold
350.
[0114] FIG. 16 illustrates a blank 422 according to a third
embodiment of the present invention. The third embodiment can be
like each of the first and second embodiments, except for
variations noted and variations that will be apparent to those of
ordinary skill in the art. Reference characters for elements of the
third embodiment that are at least generally like elements of the
first embodiment are the same, except that they are incremented by
four hundred.
[0115] The blank 422 includes flaps/side panels 430a-430d that are
foldably connected to a base panel 424, such as at fold line(s)
432. The flaps/side panels 430a-430d respectively include
protruding features 444a-444h which respectively protrude into the
corner gaps 440. The longer protruding features 444e, 444f, 444g,
444h are longer than the shorter protruding features 444a, 444b,
444c, 444d for facilitating the above-discussed predetermined
overlapping of the protruding features in a tray (e.g., tray
70).
[0116] In addition, the protruding features 444a, 444b, 444g, 444h
protrude away from a latitudinal axis 401 of the blank 422. This
protruding can help to facilitate proper positioning of the flange
portions 434a, 434c in the closed mold assembly 130. This
protruding is defined by end sections of the edges 443a, 443c of
the flaps/side panels 430a, 430c. In this regard, for each end
section of the edges 443a, 443c, a first portion of the end section
extends obliquely to, and away from, the latitudinal axis 401, and
an adjacent second portion of the end section extends obliquely to,
and toward, the latitudinal axis 401.
[0117] Similarly, the protruding features 444c, 444d, 444e, 444f
protrude away from a longitudinal axis 402 of the blank 422. This
protruding can help to facilitate proper positioning of the flange
portions 434b, 434d in the closed mold assembly 130. This
protruding is defined by end sections of the edges 443b, 443d of
the flaps/side panels 430b, 430d. In this regards, for each end
section of the edges 443b, 443d, a first portion of the end section
extends obliquely to, and away from, the longitudinal axis 402, and
an adjacent second portion of the end section extends obliquely to,
and toward, the longitudinal axis 402.
[0118] Also, the flap/side panel 430a includes a central protruding
feature 403 that helps to facilitate proper positioning of the
flange portion 434a in the closed mold assembly 130, so that the
flange portion 434a/protruding feature 403 is positioned adjacent
to the port 146 (FIG. 8A) through which molding material is
injected into the closed mold assembly 130 to form the frame 72, or
the like.
[0119] FIG. 17 is schematic, and it is like FIG. 5, except that the
cross section of FIG. 17 is taken through a tray formed from the
blank 422 (FIG. 16), in accordance with the third embodiment. FIG.
17 is illustrative of cross sections taken distant from the
outwardly protruding features 403, 444a-444h of the tray 470 of the
third embodiment. In contrast, FIG. 5 is schematically illustrative
of cross sections taken through the tray 470 of the third
embodiment at locations that are proximate the outwardly protruding
features 403, 444a-444h. In contrast to what is shown in FIG. 5,
the multi-tiered rim 484 of the tray 470 of the third embodiment
does not include the upper flange 83 (FIG. 5) in the areas that do
not include the outwardly protruding features 403, 444a-444h, and a
handle-shaped portion of the band 476 of the frame 472 takes the
place of the omitted upper flange (e.g., upper flange 83 in FIG.
5). Similarly, the upright section 485 and other portions of the
multi-tiered rim 484 may be omitted.
[0120] As mentioned above, the tray 70, is one example of a
construct (e.g., container, sleeve or other construct) of the
present invention. As alluded to above, any of the various
constructs of the present invention may optionally include one or
more features that alter the effect of microwave energy during the
heating or cooking of a food item that is associated with the
construct. For example, the construct may be formed at least
partially from (e.g., the web 54 and/or layer of microwave
interactive material 58 shown in FIGS. 2A and 2B can include) one
or more microwave energy interactive elements (hereinafter
sometimes referred to as "microwave interactive elements") that
promote browning and/or crisping of a particular area of the food
item, shield a particular area of the food item from microwave
energy to prevent overcooking thereof, or transmit microwave energy
towards or away from a particular area of the food item. Each
microwave interactive element comprises one or more microwave
energy interactive materials or segments arranged in a particular
configuration to absorb microwave energy, transmit microwave
energy, reflect microwave energy, or direct microwave energy, as
needed or desired for a particular construct and food item.
[0121] The microwave interactive element may be supported on a
microwave inactive or transparent substrate (e.g., such as, but not
limited to, the paperboard 52 or polymer film 50 shown in FIGS. 2A
and 2B) for ease of handling and/or to prevent contact between the
microwave interactive material and the food item. As a matter of
convenience and not limitation, and although it is understood that
a microwave interactive element supported on a microwave
transparent substrate includes both microwave interactive and
microwave inactive elements or components, such constructs are
referred to herein as "microwave interactive webs".
[0122] The microwave energy interactive material may be an
electroconductive or semiconductive material, for example, a metal
or a metal alloy provided as a metal foil; a vacuum deposited metal
or metal alloy; or a metallic ink, an organic ink, an inorganic
ink, a metallic paste, an organic paste, an inorganic paste, or any
combination thereof. Examples of metals and metal alloys that may
be suitable for use with the present invention include, but are not
limited to, aluminum, chromium, copper, inconel alloys
(nickel-chromium-molybdenum alloy with niobium), iron, magnesium,
nickel, stainless steel, tin, titanium, tungsten, and any
combination or alloy thereof.
[0123] Alternatively, the microwave energy interactive material may
comprise a metal oxide. Examples of metal oxides that may be
suitable for use with the present invention include, but are not
limited to, oxides of aluminum, iron, and tin, used in conjunction
with an electrically conductive material where needed. Another
example of a metal oxide that may be suitable for use with the
present invention is indium tin oxide (ITO). ITO can be used as a
microwave energy interactive material to provide a heating effect,
a shielding effect, a browning and/or crisping effect, or a
combination thereof. For example, to form a susceptor, ITO may be
sputtered onto a clear polymer film. The sputtering process
typically occurs at a lower temperature than the evaporative
deposition process used for metal deposition. ITO has a more
uniform crystal structure and, therefore, is clear at most coating
thicknesses. Additionally, ITO can be used for either heating or
field management effects. ITO also may have fewer defects than
metals, thereby making thick coatings of ITO more suitable for
field management than thick coatings of metals, such as
aluminum.
[0124] Alternatively, the microwave energy interactive material may
comprise a suitable electroconductive, semiconductive, or
non-conductive artificial dielectric or ferroelectric. Artificial
dielectrics comprise conductive, subdivided material in a polymeric
or other suitable matrix or binder, and may include flakes of an
electroconductive metal, for example, aluminum.
[0125] In one example, the microwave interactive element may
comprise a thin layer of microwave interactive material that tends
to absorb microwave energy, thereby generating heat at the
interface with a food item. Such elements often are used to promote
browning and/or crisping of the surface of a food item (sometimes
referred to as a "browning and/or crisping element"). When
supported on a film or other substrate, such an element may be
referred to as a "susceptor film" or, simply, "susceptor". However,
other microwave energy interactive elements, such as those
described herein, are contemplated hereby.
[0126] As another for example, the microwave interactive element
may comprise a foil having a thickness sufficient to shield one or
more selected portions of the food item from microwave energy
(sometimes referred to as a "shielding element"). Such shielding
elements may be used where the food item is prone to scorching or
drying out during heating.
[0127] The shielding element may be formed from various materials
and may have various configurations, depending on the particular
application for which the shielding element is used. Typically, the
shielding element is formed from a conductive, reflective metal or
metal alloy, for example, aluminum, copper, or stainless steel. The
shielding element generally may have a thickness of from about
0.000285 inches to about 0.05 inches. In one aspect, the shielding
element has a thickness of from about 0.0003 inches to about 0.03
inches. In another aspect, the shielding element has a thickness of
from about 0.00035 inches to about 0.020 inches, for example, 0.016
inches.
[0128] As still another example, the microwave interactive element
may comprise a segmented foil, such as, but not limited to, those
described in U.S. Pat. Nos. 6,204,492, 6,433,322, 6,552,315, and
6,677,563, each of which is incorporated by reference in its
entirety. Although segmented foils are not continuous,
appropriately spaced groupings of such segments often act as a
transmitting element to direct microwave energy to specific areas
of the food item. Such foils also may be used in combination with
browning and/or crisping elements, for example, susceptors.
[0129] Any of the numerous microwave interactive elements described
herein or contemplated hereby may be substantially continuous, that
is, without substantial breaks or interruptions, or may be
discontinuous, for example, by including one or more breaks or
apertures that transmit microwave energy therethrough. The breaks
or apertures may be sized and positioned to heat particular areas
of the food item selectively. The number, shape, size, and
positioning of such breaks or apertures may vary for a particular
application depending on type of construct being formed, the food
item to be heated therein or thereon, the desired degree of
shielding, browning, and/or crisping, whether direct exposure to
microwave energy is needed or desired to attain uniform heating of
the food item, the need for regulating the change in temperature of
the food item through direct heating, and whether and to what
extent there is a need for venting.
[0130] It will be understood that the aperture may be a physical
aperture or void in the material used to form the construct, or may
be a non-physical "aperture". A non-physical aperture may be a
portion of the construct that is microwave energy inactive by
deactivation or otherwise, or one that is otherwise transparent to
microwave energy. Thus, for example, the aperture may be a portion
of the construct formed without a microwave energy active material
or, alternatively, may be a portion of the construct formed with a
microwave energy active material that has been deactivated. While
both physical and non-physical apertures allow the food item to be
heated directly by the microwave energy, a physical aperture also
provides a venting function to allow steam or other vapors to be
released from the food item.
[0131] It also may be beneficial to create one or more
discontinuities or inactive regions to prevent overheating or
charring of the construct, for example, where two or more panels
abut or overlap. When exposed to microwave energy, the
concentration of heat generated by the abutted or overlapped panels
may be sufficient to cause the underlying support, in this case,
paperboard, to become scorched. As such, the abutting or
overlapping portions of one or more panels may be designed to be
microwave inactive, for example, by forming these areas without a
microwave energy interactive material or by deactivating the
microwave energy interactive material in these areas.
[0132] As stated above, any of the above elements and numerous
others contemplated hereby may be supported on a substrate. The
substrate typically comprises an electrical insulator, for example,
a polymer film or material. As used herein the term "polymer" or
"polymeric material" includes, but is not limited to, homopolymers,
copolymers, such as for example, block, graft, random, and
alternating copolymers, terpolymers, etc. and blends and
modifications thereof. Furthermore, unless otherwise specifically
limited, the term "polymer" shall include all possible geometrical
configurations of the molecule. These configurations include, but
are not limited to isotactic, syndiotactic, and random
symmetries.
[0133] The thickness of the film typically may be from about 35
gauge to about 10 mil. In one aspect, the thickness of the film is
from about 40 to about 80 gauge. In another aspect, the thickness
of the film is from about 45 to about 50 gauge. In still another
aspect, the thickness of the film is about 48 gauge. Examples of
polymer films that may be suitable include, but are not limited to,
polyolefins, polyesters, polyamides, polyimides, polysulfones,
polyether ketones, cellophanes, or any combination thereof. Other
non-conducting substrate materials such as paper and paper
laminates, metal oxides, silicates, cellulosics, or any combination
thereof, also may be used.
[0134] In one example, the polymer film comprises polyethylene
terephthalate (PET). Polyethylene terephthalate films are used in
commercially available susceptors, for example, the QWIKWAVE.RTM.
Focus susceptor and the MICRORITE.RTM. susceptor, both available
from Graphic Packaging International (Marietta, Ga.). Examples of
polyethylene terephthalate films that may be suitable for use as
the substrate include, but are not limited to, MELINEX.RTM.,
commercially available from DuPont Teijan Films (Hopewell, Va.),
SKYROL, commercially available from SKC, Inc. (Covington, Ga.), and
BARRIALOX PET, available from Toray Films (Front Royal, Va.), and
QU50 High Barrier Coated PET, available from Toray Films (Front
Royal, Va.).
[0135] The polymer film may be selected to impart various
properties to the microwave interactive web, for example,
printability, heat resistance, or any other property. As one
particular example, the polymer film may be selected to provide a
water barrier, oxygen barrier, or a combination thereof. Such
barrier film layers may be formed from a polymer film having
barrier properties or from any other barrier layer or coating as
desired. Suitable polymer films may include, but are not limited
to, ethylene vinyl alcohol, barrier nylon, polyvinylidene chloride,
barrier fluoropolymer, nylon 6, nylon 6,6, coextruded nylon
6/EVOH/nylon 6, silicon oxide coated film, barrier polyethylene
terephthalate, or any combination thereof.
[0136] One example of a barrier film that may be suitable for use
with the present invention is CAPRAN.RTM. EMBLEM 1200M nylon 6,
commercially available from Honeywell International (Pottsville,
Pa.). Another example of a barrier film that may be suitable is
CAPRAN.RTM. OXYSHIELD OBS monoaxially oriented coextruded nylon
6/ethylene vinyl alcohol (EVOH)/nylon 6, also commercially
available from Honeywell International. Yet another example of a
barrier film that may be suitable for use with the present
invention is DARTEK.RTM. N-201 nylon 6,6, commercially available
from Enhance Packaging Technologies (Webster, N.Y.). Additional
examples include BARRIALOX PET, available from Toray Films (Front
Royal, Va.) and QU50 High Barrier Coated PET, available from Toray
Films (Front Royal, Va.), referred to above.
[0137] Still other barrier films include silicon oxide coated
films, such as those available from Sheldahl Films (Northfield,
Minn.). Thus, in one example, a susceptor may have a structure
including a film, for example, polyethylene terephthalate, with a
layer of silicon oxide coated onto the film, and ITO or other
material deposited over the silicon oxide. If needed or desired,
additional layers or coatings may be provided to shield the
individual layers from damage during processing.
[0138] The barrier film may have an oxygen transmission rate (OTR)
as measured using ASTM D3985 of less than about 20 cc/m.sup.2/day.
In one aspect, the barrier film has an OTR of less than about 10
cc/m.sup.2/day. In another aspect, the barrier film has an OTR of
less than about 1 cc/m.sup.2/day. In still another aspect, the
barrier film has an OTR of less than about 0.5 cc/m.sup.2/day. In
yet another aspect, the barrier film has an OTR of less than about
0.1 cc/m.sup.2/day.
[0139] The barrier film may have a water vapor transmission rate
(WVTR) of less than about 100 g/m.sup.2/day as measured using ASTM
F1249. In one aspect, the barrier film has a water WVTR as measured
using ASTM F1249 of less than about 50 g/m.sup.2/day. In another
aspect, the barrier film has a WVTR of less than about 15
g/m.sup.2/day. In yet another aspect, the barrier film has a WVTR
of less than about 1 g/m.sup.2/day. In still another aspect, the
barrier film has a WVTR of less than about 0.1 g/m.sup.2/day. In a
still further aspect, the barrier film has a WVTR of less than
about 0.05 g/m.sup.2/day.
[0140] Other non-conducting substrate materials such as metal
oxides, silicates, cellulosics, or any combination thereof, also
may be used in accordance with the present invention.
[0141] The microwave energy interactive material may be applied to
the substrate in any suitable manner, and in some instances, the
microwave energy interactive material is printed on, extruded onto,
sputtered onto, evaporated on, or laminated to the substrate. The
microwave energy interactive material may be applied to the
substrate in any pattern, and using any technique, to achieve the
desired heating effect of the food item.
[0142] For example, the microwave energy interactive material may
be provided as a continuous or discontinuous layer or coating
including circles, loops, hexagons, islands, squares, rectangles,
octagons, and so forth. Examples of various patterns and methods
that may be suitable for use with the present invention are
provided in U.S. Pat. Nos. 6,765,182; 6,717,121; 6,677,563;
6,552,315; 6,455,827; 6,433,322; 6,414,290; 6,251,451; 6,204,492;
6,150,646; 6,114,679; 5,800,724; 5,759,422; 5,672,407; 5,628,921;
5,519,195; 5,424,517; 5,410,135; 5,354,973; 5,340,436; 5,266,386;
5,260,537; 5,221,419; 5,213,902; 5,117,078; 5,039,364; 4,963,424;
4,936,935; 4,890,439; 4,775,771; 4,865,921; and Re. 34,683, each of
which is incorporated by reference herein in its entirety. Although
particular examples of patterns of microwave energy interactive
material are shown and described herein, it should be understood
that other patterns of microwave energy interactive material are
contemplated by the present invention.
[0143] The microwave interactive element or microwave interactive
web may be joined to or overlie a dimensionally stable, microwave
energy transparent support (hereinafter referred to as "microwave
transparent support", "microwave inactive support" or "support") to
form the construct.
[0144] In one aspect, for example, where a rigid or semi-rigid
construct is to be formed, all or a portion of the support may be
formed at least partially from a paperboard material, which may be
cut into a blank prior to use in the construct. For example, the
support may be formed from paperboard having a basis weight of from
about 60 to about 330 lbs/ream (i.e., lbs/3,000 ft.sup.2), for
example, from about 80 to about 140 lbs/ream. The paperboard
generally may have a thickness of from about 6 to about 30 mils,
for example, from about 12 to about 28 mils. In one particular
example, the paperboard has a thickness of about 12 mils. Any
suitable paperboard may be used, for example, a solid bleached or
solid unbleached sulfate board, such as SUS.RTM. board,
commercially available from Graphic Packaging International.
[0145] In another aspect, where a more flexible construct is to be
formed, the support may comprise a paper or paper-based material
generally having a basis weight of from about 15 to about 60
lbs/ream, for example, from about 20 to about 40 lbs/ream. In one
particular example, the paper has a basis weight of about 25
lbs/ream.
[0146] Optionally, one or more portions of the various blanks
(e.g., the substrate, or more specifically the paperboard 52 which
is formed from cellulosic material) or other constructs described
herein or contemplated hereby may be coated with varnish, clay, or
other materials, either alone or in combination. The coating may
then be printed over with product advertising or other information
or images. The blanks or other constructs also may be coated to
protect any information printed thereon. Typically, the margin of
the blank will not be coated or printed with ink or any other
material that may have an adverse effect on the adhesion of the
frame 72, or the like, to the blank. That is, ink will typically be
omitted from the blank in the areas in which the blank and frame 72
overlap. Typically, any ink or microwave interactive materials are
applied to the blank prior to forming the frame 72 onto the
blank/construct/tray, although other sequences can be
acceptable.
[0147] Furthermore, the blanks or other constructs may be coated
with, for example, a moisture and/or oxygen barrier layer, on
either or both sides, such as those described above. Any suitable
moisture and/or oxygen barrier material may be used in accordance
with the present invention. Examples of materials that may be
suitable include, but are not limited to, polyvinylidene chloride,
ethylene vinyl alcohol, DuPont DARTEK.TM. nylon 6,6, and others
referred to above.
[0148] Alternatively or additionally, any of the blanks or other
constructs of the present invention may be coated or laminated with
other materials to impart other properties, such as absorbency,
repellency, opacity, color, printability, stiffness, or cushioning.
For example, absorbent susceptors are described in U.S. Provisional
Application No. 60/604,637, filed Aug. 25, 2004, and U.S. patent
application Ser. No. 11/211,858, to Middleton, et al., titled
"Absorbent Microwave Interactive Packaging", filed Aug. 25, 2005,
both of which are incorporated herein by reference in their
entirety. Additionally, the blanks or other constructs may include
graphics or indicia printed thereon.
[0149] It will be understood that with some combinations of
elements and materials, the microwave interactive element may have
a grey or silver color that is visually distinguishable from the
substrate or the support. However, in some instances, it may be
desirable to provide a web or construct having a uniform color
and/or appearance. Such a web or construct may be more
aesthetically pleasing to a consumer, particularly when the
consumer is accustomed to packages or containers having certain
visual attributes, for example, a solid color, a particular
pattern, and so on. Thus, for example, the present invention
contemplates using a silver or grey toned adhesive to join the
microwave interactive elements to the substrate, using a silver or
grey toned substrate to mask the presence of the silver or grey
toned microwave interactive element, using a dark toned substrate,
for example, a black toned substrate, to conceal the presence of
the silver or grey toned microwave interactive element,
overprinting the metalized side of the web with a silver or grey
toned ink to obscure the color variation, printing the
non-metalized side of the web with a silver or grey ink or other
concealing color in a suitable pattern or as a solid color layer to
mask or conceal the presence of the microwave interactive element,
or any other suitable technique or combination thereof.
[0150] As mentioned above, numerous differently configured
constructs are within the scope of the present invention. As one
last example, the tray 70 could be configured so that it includes
multiple compartments, and the compartments can respectively
include (or be associated with) microwave energy interactive
material with different characteristics. More specifically, one of
the compartments can include shielding elements, another
compartment can include a susceptor, and another compartment can
include a transmitting element. Other variations between
compartments are also within the scope of the present
invention.
[0151] In accordance with the exemplary embodiments of the present
invention, the blanks can be formed from paperboard, corrugated
cardboard or other materials having properties suitable for at
least generally enabling respective functionalities described
above. Paperboard is typically of a caliper such that it is heavier
and more rigid than ordinary paper, and corrugated cardboard is
typically of a caliper such that it is heavier and more rigid than
paperboard. Typically, at least the side of the paperboard or
cardboard that will be an exterior surface in the carton erected
therefrom will be coated with a clay coating, or the like. The clay
coating can be printed over with product, advertising,
price-coding, and other information or images. The blanks may then
be coated with a varnish to protect any information printed on the
blanks. The blanks may also be coated with, for example, a moisture
barrier layer, on one or both sides. The blanks can also be
laminated to or coated with one or more sheet-like materials.
[0152] In accordance with the exemplary embodiments of the present
invention, a fold line can be any at least somewhat line-like
arranged, although not necessarily straight, form of weakening that
facilitates folding therealong; and a tear line can be any at least
somewhat line-like arranged, although not necessarily straight,
form of weakening that facilitates tearing therealong. More
specifically, but not for the purpose of narrowing the scope of the
present invention, conventional fold lines include: a crease, such
as formed by folding; a score line, such as formed with a blunt
scoring knife, or the like, which creates a crushed portion in the
material along the desired line of weakness; a slit that extends
partially into the material along the desired line of weakness,
and/or a series of spaced apart slits that extend partially into
and/or completely through the material along the desired line of
weakness; or various combinations of these features.
[0153] It will be understood by those skilled in the art that while
the present invention has been discussed above with reference to
exemplary embodiments, various additions, modifications and changes
can be made thereto without departing from the spirit and scope of
the invention as set forth in the following claims.
* * * * *